In Line Phased Array Inspection of Encapsulated Battery Structural Adhesives
Inline phased array testing maps structural adhesive wet-out and void formation through metal pack enclosures in real time at production line speeds.
Aluminum Tray Substrate
Meaning
Structural frame provides the physical foundation and thermal interface for individual battery cells or modules. Integrating an aluminum tray substrate into a pack design allows for high mechanical rigidity and efficient weight reduction compared to steel alternatives. It protects the internal components from external impacts and vibrations.
Thermal Management
Dissipation of heat occurs through the metallic surface to external cooling channels or ambient air. The aluminum tray substrate acts as a heat sink to prevent the buildup of thermal energy during fast charging. Precision machining or extrusion ensures the surface is flat enough to maintain contact with thermal interface materials.
Fabrication Process
Joining various parts of the assembly involves friction stir welding or structural adhesives. Using an aluminum tray substrate requires careful control over alloy selection to prevent corrosion or stress cracking. The material is often treated with a non-conductive coating to provide electrical insulation from the high-voltage circuits.
This coating must endure extreme temperature cycles without delaminating or losing its dielectric strength.
Safety Function
Protection of the battery cells from puncture or crushing depends on the wall thickness and geometry of the part. An aluminum tray substrate must meet specific crashworthiness standards for automotive applications. It defines the boundary between the energy storage system and the vehicle chassis.